Dry friction damped mechanical and structural metal components and methods of manufacturing the same

Abstract

A method and system for increasing damping capacity in cast metal parts by utilizing dry friction between individual wires of a sheathed rope is disclosed. The rope is embedded into the part during casting. Sheathing the ropes in a thin layer of the same metal as the casting prevents molten metal from infiltrating individual wires during casting, thus allowing inter-wire friction during the part vibration. There are two ways to distribute the ropes within a part during casting. The first way is to distribute the ropes uniformly across an entire part whereby damping capacity of the metal part increases uniformly as well. The second way of distributing the ropes is to spatially distribute them according to a pattern to increase the damping capacity only in the part regions that have the highest vibration amplitudes or stress during system vibration. Both methods of distribution may be combined in a single part.

What is claimed is: 
     
       1. A vibration-dampener for use in a cast metal component comprising:
 a rope having first and second ends, said rope comprising a plurality of wires positioned next to one another, said first end and said second end are joined, thereby forming a rope ring; and 
 a metal sheathing encasing said plurality of wires to form said rope, said sheathing having a melting point equal to or greater than the casting alloy, whereby sliding movement of the surfaces of the wires relative to one another dampens resonant vibration of the component; 
 wherein said rope ring is embedded within a ring-shaped insert. 
 
     
     
       2. The vibration-dampener of  claim 1  further including at least one locator tab attached to said rope and extending therefrom. 
     
     
       3. The vibration-dampener of  claim 1  wherein said rope is formed within an insert which is cast in the cast metal component. 
     
     
       4. The vibration-dampener of  claim 3  further including a locator tab extending from said insert. 
     
     
       5. The vibration-dampener of  claim 1  wherein said wires are arranged linearly or helically. 
     
     
       6. The vibration-dampener of  claim 1  wherein plural ring-shaped inserts are provided within the cast metal component. 
     
     
       7. A vibration-dampener for use in a cast metal component comprising:
 a rope having first and second ends, said rope comprising a plurality of wires positioned next to one another, said first end and second end are joined, thereby forming a rope ring; and 
 a metal sheathing completely wrapped around said plurality of wires to form said rope, whereby sliding movement of the surfaces of the wires relative to one another dampens the resonant vibration of the component, 
 wherein said rope ring is embedded within a ring-shaped insert. 
 
     
     
       8. The vibration-dampener of  claim 7  in which said metal sheathing has a melting point equal to or greater than that of the casting alloy. 
     
     
       9. The vibration-dampener of  claim 7  further including at least one locator tab attached to said rope and extending therefrom. 
     
     
       10. The vibration-dampener of  claim 7  wherein said rope is formed within an insert which is cast in the cast metal component. 
     
     
       11. The vibration-dampener of  claim 10  further including a locator tab extending from said insert. 
     
     
       12. The vibration-dampener of  claim 7  wherein said wires are arranged linearly or helically. 
     
     
       13. The vibration-dampener of  claim 7  wherein plural ring-shaped inserts are provided within the cast metal component.